EP3476473A1 - Réacteur de type à écoulement - Google Patents

Réacteur de type à écoulement Download PDF

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Publication number
EP3476473A1
EP3476473A1 EP17815513.1A EP17815513A EP3476473A1 EP 3476473 A1 EP3476473 A1 EP 3476473A1 EP 17815513 A EP17815513 A EP 17815513A EP 3476473 A1 EP3476473 A1 EP 3476473A1
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Prior art keywords
reactor
unit
reactor unit
flow
fluororesin
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
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EP17815513.1A
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German (de)
English (en)
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EP3476473A4 (fr
Inventor
Shiori OZASA
Tomoyuki Toyoda
Takahiro Ohishi
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Kaneka Corp
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Kaneka Corp
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Publication of EP3476473A1 publication Critical patent/EP3476473A1/fr
Publication of EP3476473A4 publication Critical patent/EP3476473A4/fr
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J14/00—Chemical processes in general for reacting liquids with liquids; Apparatus specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053—Details of the reactor
    • B01J19/0066—Stirrers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0093—Microreactors, e.g. miniaturised or microfabricated reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/02—Apparatus characterised by being constructed of material selected for its chemically-resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2415—Tubular reactors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K3/04—Carbon
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08K3/22—Oxides; Hydroxides of metals
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C08L101/04—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing halogen atoms
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    • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
    • C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20—Conductive material dispersed in non-conductive organic material
    • H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20—Conductive material dispersed in non-conductive organic material
    • H01B1/24—Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00245—Avoiding undesirable reactions or side-effects
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2219/00245—Avoiding undesirable reactions or side-effects
    • B01J2219/00272—Addition of reaction inhibitor
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    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00819—Materials of construction
    • B01J2219/00833—Plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00851—Additional features
    • B01J2219/00867—Microreactors placed in series, on the same or on different supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/0095—Control aspects
    • B01J2219/00952—Sensing operations
    • B01J2219/00954—Measured properties
    • B01J2219/00961—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/02—Apparatus characterised by their chemically-resistant properties
    • B01J2219/0204—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components
    • B01J2219/0245—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components of synthetic organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/02—Apparatus characterised by their chemically-resistant properties
    • B01J2219/025—Apparatus characterised by their chemically-resistant properties characterised by the construction materials of the reactor vessel proper
    • B01J2219/0295—Synthetic organic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/19—Details relating to the geometry of the reactor
    • B01J2219/194—Details relating to the geometry of the reactor round
    • B01J2219/1941—Details relating to the geometry of the reactor round circular or disk-shaped
    • B01J2219/1943—Details relating to the geometry of the reactor round circular or disk-shaped cylindrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/19—Details relating to the geometry of the reactor
    • B01J2219/194—Details relating to the geometry of the reactor round
    • B01J2219/1941—Details relating to the geometry of the reactor round circular or disk-shaped
    • B01J2219/1944—Details relating to the geometry of the reactor round circular or disk-shaped spiral
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K3/08—Metals
    • C08K2003/0831—Gold
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K2003/085—Copper
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K2003/0856—Iron
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2231—Oxides; Hydroxides of metals of tin
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2296—Oxides; Hydroxides of metals of zinc

Definitions

  • the present invention relates to a flow reactor. More specifically, the present invention relates to a flow reactor wherein at least a part of the inner wall of a reactor unit is formed of a fluororesin containing a conductive filler.
  • a micro-flow reactor is a chemical reaction apparatus generally utilizing a microchannel in the order of submillimeter as a reaction field.
  • the micro-flow reactor has attracted attention in recent years because it has specific effects, due to the micro reaction field, such as high-speed mixing performance (for example, when two liquids are mixed in a micro-space, the substance diffusion distance in the two liquids decreases, resulting in shortening the time of mass transfer movement), heat removal efficiency (since the reaction field is small, thermal efficiency is extremely high and temperature control is easy), reaction control performance, interface control performance, or the like.
  • micro-flow reactor provides various effects such as improved safety and significantly reduced cost of equipment along with downsizing of the whole process, process intensification (micro in macro) by incorporating into existing processes, and production of substances that could not be produced by an existing production method.
  • the flow reactor is a chemical reaction apparatus in which the diameter of a flow channel is enlarged to the order of millimeters to centimeters to the extent that the characteristics of the micro-flow reactor are not impaired to enhance the operability.
  • the flow reactor is mainly composed of a raw material feeding unit, a reaction unit, and an operation control unit, and as base materials for these units, inorganic materials such as metals, silicon, glass, and ceramic, or organic materials such as resins are generally used.
  • Patent Document 1 discloses a method for continuously producing polymers by polymerization of RAFT solution using a flow reactor, and the flow reactor is made of a polymer, metal, glass or combination thereof.
  • Patent Document 2 discloses a microchannel structure in which glass, Teflon (registered trademark), a metal, or the like, which is resistant to a highly corrosive liquid such as an acid and alkali, is used for substrates.
  • Patent Document 3 discloses the fluororesin coated surfaces of loaded parts of a device such as a distillation column, in which a fluid containing an easily polymerizable substance are handled.
  • Patent Document 4 discloses a reactor having an inner metal wall having a fluoropolymer coating fixedly attached thereto.
  • Patent Document 5 discloses a structure for storing and transporting chemical products such as corrosive products, the structure having a multilayer structure including an inner layer of irradiation-grafted fluoropolymer and an outer layer of a polyolefin directly attached to the inner layer.
  • Patent Document 6 discloses a multilayer pipe that is preferably used for transporting petrol, the multilayer pipe having a multilayer structure including an inner layer of irradiation-grafted fluoropolymer and an outer layer of a polyolefin directly attached to the inner layer.
  • Patent Document 7 discloses a laminated tube composed of at least three layers including a layer formed of a fluorine-containing polymer.
  • An object of the invention is to provide a flow reactor that enables the use of the substance having an electrostatic charge property such as the organic solvent having a low dielectric constant and that is also excellent in corrosion resistance.
  • the inventors have found that by allowing at least a part of the inner wall of a reactor unit in a flow reactor to be formed of a fluororesin containing a conductive filler, the risk of electrostatic ignition is avoided, whereby it is possible to obtain the flow reactor that enables the use of the substance having an electrostatic charge property such as the organic solvent having a low dielectric constant and that is also excellent in corrosion resistance.
  • the flow reactor according to the present invention has one or more features described below.
  • the flow reactor of the present invention since at least a part of the inner wall is formed of the fluororesin containing the conductive filler, it is possible to use a substance having an electrostatic charge property and a corrosive substance. Moreover, in the case of the flow reactor, the whole process becomes compact. Therefore, the retaining amount of hazardous substances can be minimized, resulting in the improvement of safety. In addition, equipment costs can be drastically reduced, and thus a process with excellent competitiveness can be constructed.
  • FIG. 1 is a schematic view showing an example of the configuration of a flow reactor adopted in the present invention, and the example shown in FIG. 1 is the most basic example.
  • the flow reactor includes two or more raw material feeding units (two raw material feeding units 1a and 1b in the example shown in the drawing), a mixing unit 2 (T-shape mixer in the example shown in the drawing) to mix raw materials fed from the raw material feeding units, a reactor unit 3 in which a mixed solution prepared in the mixing unit 2 flows. A reaction proceeds while the solution is transferred through the reactor unit 3 (linear reactor unit in the example shown in the drawing).
  • the raw material feeding units 1a and 1b are respectively connected to raw material storage containers 4a and 4b to store respective raw materials.
  • the raw material feeding units 1a and 1b are respectively provided with liquid feeding control units (preferably diaphragm pumps) 5a and 5b, and the mixed solution flows in the reactor unit 3 by the pressure generated by these liquid feeding control units 5a and 5b.
  • a reaction liquid discharged from the reactor unit 3 is temporarily stored in a reaction liquid storage container 6.
  • the flow reactor that can be adopted in the present invention as described above is characterized in that at least a part of the inner wall of the reactor unit is formed of a fluororesin containing a conductive filler.
  • the fluororesin contains the conductive filler, so that the risk of electrostatic ignition can be avoided, whereby it becomes possible to fabricate a flow reactor that enables the use of the substance having an electrostatic charge property such as an organic solvent having a low dielectric constant and that is also excellent in corrosion resistance.
  • a fluororesin is lightweight and soft, workers can flexibly bend the flow reactor and also perform a manual attachment at production sites, and hence there is an advantage in that workability is greatly improved.
  • there are advantages in that a market price per unit length of a fluororesin is significantly low in comparison with alloys such as Hastelloy and Monel, and the replacement work is also simplified.
  • the volume resistivity of the fluororesin itself which is usually 1.0 ⁇ 10 16 to 1.0 ⁇ 10 18 ⁇ •m (JIS K 6911; 50% RH, 23°C), is higher than that of common thermoplastic resins such as polypropylene, and therefore the fluororesin tends to be charged easily alone.
  • the conductive filler is included in the fluororesin to reduce the risk of electrostatic ignition.
  • using the fluororesin it becomes possible to provide a process at a lower cost as compared with the case where a metal having excellent corrosion resistance is used.
  • the conductive filler is contained in the fluororesin, and for example, it is desirable that the conductive filler be kneaded into the fluororesin.
  • the linear velocity of a reaction liquid flowing through a flow channel tends to become high, and there is concern that the conductive filler may fall off due to friction between the reaction liquid and the inner wall. Therefore, in order to prevent the conductive filler from falling off, the conductive filler may be kneaded into the fluororesin.
  • the fluororesin is a homopolymer or a copolymer produced from a fluorine atom-containing monomer.
  • the homopolymer produced from a fluorine atom-containing monomer include polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), polyvinylidene-fluoride (PVDF), polyvinyl fluoride (PVF), and the like.
  • Examples of the copolymer produced from a fluorine atom-containing monomer include perfluoroethylene propene copolymer (FEP), perfluoroalkoxyalkane (PFA), tetrafluoroethylene-perfluorodioxole copolymer (TFE/PDD), ethylene-chlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE), tetrafluoroethylene-perfluoro (alkyl vinyl ether)-chlorotrifluoroethylene copolymer (CPT), ethylene-tetrafluoroethylene-hexafluoropropene copolymer (EFEP), and the like. These may be used singly or in combination of two or more.
  • FEP perfluoroethylene propene copolymer
  • PFA perfluoroalkoxyalkane
  • TFE/PDD tetrafluoroethylene-perfluorodiox
  • PTFE, PCTFE, FEP, PFA, ECTFE and ETFE are preferable, and PTFE, FEP and PFA are more preferable.
  • PCTFE PCTFE
  • PVF polyvinylene
  • FEP polyvinylene
  • PFA polymethyl methacrylate
  • ECTFE ECTFE
  • ETFE ECTFE
  • the fluororesin since the fluororesin is used as the inner wall of the reactor unit, the fluororesin desirably has both chemical resistance and formability, and PFA is particularly preferable as the fluororesin.
  • the temperature of inside the reactor may rise depending on the type of reaction, a fluororesin with a higher melting point is preferable, and for example, the melting point is preferably 150°C or higher, more preferably 200°C or higher, and further preferably 240°C or higher.
  • the upper limit thereof is not particularly limited, but is usually 350°C or lower.
  • a metal or carbon which is known as a conductor
  • a metal or carbon which is known as a conductor
  • specific examples thereof include carbon-based fillers such as carbon black, ketjen black, acetylene black, carbon nanotubes, natural graphite, artificial graphite, and vapor-grown carbon fibers; metal-based fillers such as gold, silver, nickel, copper, zinc, aluminum, and stainless steel; metal oxide-based fillers such as aluminum-doped zinc oxide, antimony-doped tin oxide (IV), and tin-doped indium oxide (III); and metal alloy-based fillers such as AgCu, AgSn, CuZn, CuNiZn, and CuNi. These may be used singly or in combination of two or more.
  • the reactor unit containing the fluororesin is inferior in durability as compared with a reactor unit made of a metal, and hence when the reactor unit containing the fluororesin is used, the frequency of replacement of the reactor unit tends to rise as compared with the case of using the reactor unit made of a metal. Therefore, the conductive filler used in the reactor unit is preferably a carbon-based filler, which has easy availability, excellent conductivity and compatibility with chemical reagent.
  • the conductive filler is preferably in the shape of a sphere or needle.
  • the lower limit of the average particle size of the conductive filler is preferably 5 nm or more, and more preferably 10 nm or more.
  • the upper limit of this average particle size is preferably 500 nm or less, and more preferably 100 nm or less.
  • the average particle size can be evaluated based on an average value of particle diameters measured by a laser diffraction/scattering method, which is a general technique, or measured by using scanning microscope photographs for 100 to 1000 randomly selected fillers.
  • the conductive filler is preferably in the shape of a needle that facilitates the formation of a conductive path.
  • the lower limit of the aspect ratio (length/diameter of a filler) of the conductive filler in the shape of a needle is preferably 5 or more, and more preferably 10 or more.
  • the upper limit of this aspect ratio is preferably 500 or less, and more preferably 100 or less.
  • the content of the conductive filler is preferably 5 parts by weight or more, and more preferably 7 parts by weight or more in 100% by weight of the fluororesin.
  • the upper limit of the content of the conductive filler is preferably 30 parts by weight or less, and more preferably 20 parts by weight or less.
  • the fluororesin containing the conductive filler is excellent in antistatic properties and has a volume resistivity (JIS K 6911; 50% RH, 23°C) of preferably 10 6 ⁇ •m or less, more preferably 10 5 ⁇ •m or less, and further preferably 10 4 ⁇ •m or less.
  • the lower limit of the volume resistivity of the fluororesin containing the conductive filler is not particularly limited, but is usually 0 ⁇ •m or more.
  • the surface resistivity (JIS K 6911; 50% RH, 23°C) of the fluororesin containing the conductive filler is preferably 10 6 ⁇ or less, and more preferably 10 5 ⁇ or less.
  • the lower limit thereof is not particularly limited, but is usually 0 ⁇ or more.
  • the "at least a part of the inner wall of the reactor unit is formed of a fluororesin containing a conductive filler” specifically means that the fluororesin containing the conductive filler is present in at least a part of the inner wall surface of the reactor unit that is in contact with a content liquid contained in the reactor unit.
  • FIGs. 2(a) to 2(d) show preferred embodiments in which at least a part of the inner wall is formed of the fluororesin containing the conductive filler.
  • a reactor unit being the shape of a tube and having circular cross section are taken as examples, and the cross sections of the reactor unit are illustrated but the shape of the cross-section of the reactor unit is not limited to these examples.
  • the inner wall of the reactor unit be configured such that the entire inner wall of the reactor unit is formed of a fluororesin 70 containing a conductive filler as shown in FIG. 2(a) and FIG. 2(b) , or such that a part of the inner wall of the reactor unit is formed of the fluororesin 70 containing the conductive filler, and the remaining part of the inner wall is formed of a second resin 71 as shown in FIG. 2(c) and FIG. 2(d) .
  • a smaller number of joints between the fluororesin 70 containing the conductive filler and the second resin 71 is preferable. Therefore, it is more preferable that the inner wall of the reactor unit be configured such that the entire inner wall of the reactor unit is formed of the fluororesin 70 containing the conductive filler ( FIG. 2(a) and FIG. 2(b) ).
  • the whole of the reactor unit may be formed of the fluororesin 70 with conductivity as shown in FIG. 2(a) , or the reactor unit may be formed of the fluororesin 70 with conductivity and the second resin 71 as shown in FIGs. 2(b) to 2(d) .
  • the second resin 71 may cover the outer circumferential surface of the reactor unit ( FIGs. 2(b) to 2(d) ) and may form a part of the inner wall of the reactor unit ( FIG. 2(c) and FIG. 2(d) ).
  • grounding needs to be established at an appropriate point such as a midpoint of a flow channel or a connecting portion to dissipate static electricity generated on the inner wall of the flow channel to the outside.
  • the second resin (excluding the fluororesin containing the conductive filler), for example, a fluororesin containing no conductive filler is preferably used, and as such a fluororesin, the same fluororesins as the above-mentioned fluororesins can be used.
  • the fluororesin is also used as the second resin, whereby the reactor unit excellent in chemical resistance can be obtained.
  • the fluororesin containing the conductive filler is preferably exposed at a degree of 50% or more, more preferably 70% or more, further preferably 90% or more, and particularly preferably 100% of the inner wall surface.
  • the cross-section of the reactor unit may have a single-layer structure composed of the fluororesin containing the conductive filler ( FIG. 2(a) ) or a multilayer structure composed of the fluororesin containing the conductive filler ( FIGs 2(b) to 2(d) ). From the viewpoint of improving the antistatic effect, the cross-section of the reactor unit desirably has a single-layer structure composed of the fluororesin containing the conductive filler.
  • the shape of the reactor unit there is no particular limitation on the shape of the reactor unit as long as the reactor unit is in a shape through which a reaction liquid can flow.
  • a hollow and columnar tube-type reactor, and a laminate-type reactor having a substrate in which a groove corresponding to a flow channel is formed by etching or the like can be given.
  • the cross section of a flow channel may be circular, polygonal, or distorted circular (for example, convex or concave), and the circular or polygonal cross section is more preferable.
  • the tube-type reactor may have a single-tube structure or a multiple-tube structure in which an inner tube is inserted into an outer tube like a double-cylindrical tube.
  • the length of the reactor unit is preferably 1 cm or more, and more preferably 10 cm or more.
  • the upper limit of the length of the reactor unit is not particularly limited, but is preferably 500 m or less, and more preferably 300 m or less.
  • the length of the tube is preferably twice or more, more preferably 10 times or more, and further preferably 15 times or more the equivalent diameter of the flow channel.
  • the upper limit of the length of the tube is not particularly limited, but is preferably 10,000 times or less, more preferably 5,000 times or less, and further preferably 3,000 times or less the equivalent diameter of the flow channel. Adjusting the size of the tube within the above range makes it easier for the contents to come into contact with the inner wall of the reactor unit, and problems caused by electrostatic charge can be prevented.
  • the equivalent diameter of the flow channel of the reactor unit is preferably 50 mm or less, more preferably 20 mm or less, and further preferably 15 mm or less. In view of pressure drop and processing amount, it is preferably 0.1 mm or more, more preferably 1.0 mm or more, and further preferably 1.5 mm or more.
  • the number of flow channels in the reactor unit is not particularly limited, and one or two or more (preferably, ten or less) flow channels are provided.
  • the reactor unit may have a structure in which, from the upstream side toward the downstream side, two or more (preferably two) flow channels merge into one flow channel, or a structure in which, from the upstream side toward the downstream side, one flow channel branches into two or more (preferably two) flow channels. It is desirable that two or more flow channels be provided more preferably in a tournament format.
  • the inner walls of the reactor units in all the flow channels are not necessarily formed of the fluororesin with conductivity.
  • the reaction product may have conductivity or may lose corrosivity. Therefore, depending on the properties of the liquid after the reactions, the inner wall of the reactor unit may be formed of a material other than the fluororesin with conductivity.
  • the inner wall of the reactor unit is preferably formed of, for example, inorganic substances such as metals, silicon, glass and ceramic, or organic substances such as resins according to the characteristics of the reaction product.
  • the equivalent diameter of the flow channel of the reactor unit may be uniform throughout the whole reactor unit or may be changed in the middle of the reactor unit. If the equivalent diameter of the flow channel of the reactor unit is uniform, the reaction proceeds evenly without the flow of the reaction liquid being hindered. On the other hand, taking various conditions such as mixing performance and heat removal efficiency into consideration, the equivalent diameter of the flow channel of the reactor unit may be changed in the middle of the reactor unit.
  • the equivalent diameter of the flow channel may be changed at an arbitrary position, the number of times of changing the equivalent diameter of the flow channel is not limited, and the equivalent diameter of the flow channel may be changed once or twice or more as necessary. Furthermore, the equivalent diameter of the flow channel may be gradually changed or may be greatly changed with a certain point being as the border.
  • the equivalent diameter of the flow channel may be smaller or may be larger than the equivalent diameter of the flow channel on the upstream side, and may be appropriately designed according to the reaction.
  • the design of the flow channel is not limited to the following example. However, for example, since the mixing efficiency improves as the equivalent diameter of the flow channel of the reactor unit decreases, it is also possible that the equivalent diameter of the flow channel of the reactor unit positioned after the mixing unit is made small, and after sufficient mixing, the equivalent diameter of the flow channel of the reactor unit is made large.
  • the tube thickness of the reactor unit also may be uniform throughout the whole reactor unit or may be changed in the middle of the reactor unit. If the tube thickness of the reactor unit is made thin, the structure in which heat can be easily removable, and heat removal efficiency improves. If the tube thickness of the reactor unit is thin, the cooling efficiency also increases.
  • the outer diameter of the reactor unit may also be uniform throughout the whole reactor unit or may be changed in the middle of the reactor unit. Since the heat removal efficiency improves as the outer diameter of the reactor unit decreases, for example, for a portion requiring a precise temperature control, both the equivalent diameter of the flow channel of the reactor unit and the outside diameter of the reactor unit may be decreased. Alternatively, by increasing only the equivalent diameter of the flow channel and making the outer diameter of the reactor unit uniform, the tube thickness of the reactor unit is made thin, so that the structure in which can be heat easily escapes can be obtained.
  • the outer diameter of the reactor unit in the present invention refers to the outer equivalent diameter of the tube-type reactor.
  • the tube thickness of the reactor unit indicates the thickness of the fluororesin with conductivity and/or other materials constituting the flow channel of the tube-type reactor.
  • the ratio (D max / D min ) of the maximum equivalent diameter (D max ) to the minimum equivalent diameter (D min ) in the reactor unit is preferably 1.10 times or less, more preferably 1.05 times or less, further preferably 1.01 times or less, and preferably 1.0 times or more.
  • the ratio (D max / D min ) of the maximum equivalent diameter (D max ) to the minimum equivalent diameter (D min ) is preferably 1.10 times or more, more preferably 1.20 times or more, and further preferably 1.30 times or more.
  • the upper limit of the ratio is preferably 10 times or less, and more preferably 5 times or less.
  • the reactor unit 3 is preferably line shape, it does not necessarily have to be in the shape of a straight line as shown in FIG. 1 .
  • the reactor unit may be a reactor unit 31 wound in the shape of a spiral or coil as shown in FIG. 3 , or may be a reactor unit 32 with several bent backs as shown in FIG. 4 .
  • the reactor unit 3 is preferably in a shape with an unvaried curvature like the shape of a straight line, spiral, coil, or the like. Non-uniformity in flow can be prevented by making the reactor unit in the shape having an unvaried curvature.
  • the axial direction of the spiral or coil is not particularly limited, and may be parallel to the direction of gravity or perpendicular to the direction of gravity, but is more preferably parallel to the direction of gravity.
  • the reactor unit has a reactor inlet for introducing a raw material into the reactor unit and a reactor outlet for discharging a product produced in the reactor unit to the outside of the reactor unit.
  • the installation positions of the reactor inlet and the reactor outlet are not particularly limited.
  • the reactor inlet may be placed at the same height as the reactor outlet, at a position higher than the position of the reactor outlet, or at a position lower than the position of the reactor outlet.
  • a reaction liquid containing a solvent with a low dielectric constant can contact the inner wall of the reactor unit as much as possible.
  • the reactor inlet is desirably placed at a position lower than the position of the reactor outlet. If the reactor inlet is placed at a position lower than the position of the reactor outlet, bubbles contained in the reaction liquid are entrained by the flow of the reaction liquid and discharged from the upper part of the reactor unit, so that bubbles hardly adhere to the inner wall of the reactor unit. As a result, it is possible to efficiently bring the reaction liquid into contact with the inner wall of the reactor unit.
  • the fluororesin tends to have a lower contents' hermeticity than that of other flexible resins, and even when the cross-section of the reactor unit has a single-layer structure composed of the fluororesin containing the conductive filler, there is a risk that the inner solution may ooze out through the fluororesin to the outside.
  • the outer wall surface of the reactor unit may be brought into contact with a quenching agent. Even if the reaction solution oozes out, safety can be ensured by using a quenching agent.
  • a toxic substance such as acrylonitrile, acrolein, sulfur dioxide gas, arsine, ammonia, carbon monoxide, chlorine, chloromethine, chloroprene, arsenic pentafluoride, phosphorus pentafluoride, ethylene oxide, nitrogen trifluoride, boron trifluoride, phosphorus trifluoride, hydrogen cyanide, diethylamine, disilane, sulfur tetrafluoride, silicon tetrafluoride, diborane, hydrogen selenide, trimethylamine, carbon disulfide, fluorine, bromomethyl, phosgene, phosphine, monogermane, monosilane, monomethylamine, or hydrogen sulfide is used, the outer wall surface of the reactor unit may be brought into contact
  • water As the quenching agent, water; an acidic aqueous solution containing at least one acid selected from hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid, citric acid and the like; an alkaline aqueous solution containing at least one base selected from sodium hydroxide, potassium carbonate and sodium hydrogen carbonate; an oxidizing aqueous solution such as hydrogen peroxide, a sodium hypochlorite aqueous solution, a sodium chlorite aqueous solution or the like; a reducing aqueous solution such as a sodium thiosulfate aqueous solution, sodium sulfite aqueous solution or the like can be exemplified.
  • an acidic aqueous solution containing at least one acid selected from hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid, citric acid and the like
  • the flow reactor adopted in the present invention may have two or more (for example, three) raw material feeding units according to a reaction method. As shown in FIG. 5 , raw materials fed from either one or both raw material feeding units may be a resultant product obtained by preliminarily mixing other raw materials 14a and 14b in a premixer 12 and then reacting them as necessary. Although not shown, the reaction liquid discharged from the reactor unit 3 may be used as a raw material for a subsequent flow reactor. The reaction raw materials (including the preliminary reactant) are fed into the flow reactor through these raw material feeding units. The reaction raw materials are usually fed in the form of liquid (including solution).
  • the reaction raw materials are preferably fed by a liquid feeding control unit such as a diaphragm pump.
  • the number of liquid feeding control units is not particularly limited and may be equal to or greater than or less than the number of the raw material feeding units.
  • the liquid feeding control unit is not limited to a pump, and for example, a pressurized container to charge a reaction raw material can also be used as the liquid feeding control unit.
  • the raw material feeding unit is preferably a tube, and the inner diameter of the tube is preferably 0.01 mm or more, more preferably 0.1 mm or more, and preferably 50 mm or less.
  • One end of the raw material feeding unit is connected to a raw material feeding port and the other end is connected to the mixing unit.
  • the mixing unit is a unit to mix raw materials, and is placed, for example, between the ends of two or more raw material feeding units and the reactor inlet.
  • the mixed solution obtained in the mixing unit is fed as a reaction liquid into the reactor unit through the reactor inlet.
  • the mixing unit is preferably a tube, and the inner diameter of the tube is preferably 0.01 mm or more and 50 mm or less.
  • a known mixer may be provided in the mixing unit in order to sufficiently stir the raw materials.
  • Examples of such a mixer include a T-shape mixer, a Y-shape mixer, a static mixer, a helix-type mixer, and the like.
  • the discharge unit is a unit through which products produced in the reactor unit and unreacted raw materials flow.
  • the discharge unit is also preferably a tube, and the inner diameter of the tube is preferably 0.01 mm or more, more preferably 0.1 mm or more, and preferably 50 mm or less. It is desirable that the reaction solution collected from the discharge unit be appropriately processed thereafter.
  • the raw material feeding unit, the mixing unit and the discharge unit are preferably made from a metal such as stainless steel, Hastelloy, titanium, copper, nickel, or aluminum; an inorganic material such as glass or ceramic; or a resin such as PEEK resin, silicone resin, or fluororesin. Electrical conductivity may be imparted to the resin. From the viewpoint of corrosion resistance, heat resistance and durability, the metal, particularly Hastelloy, is preferable.
  • the raw material feeding unit, the mixing unit, and the discharge unit may have either a single-layer structure or a multilayer structure. From the viewpoint of prevention of liquid leakage, at least one or all of the raw material feeding unit, the mixing unit, and the discharge unit desirably have a multilayer structure.
  • the flow reactor has a larger specific surface area and better heat transfer performance as compared with those of a batch reactor, and thus temperature control can be performed quickly. Therefore, the flow reactor is desirably provided with a temperature control unit.
  • the temperature control unit is preferably capable of adjusting a temperature of at least one of the raw material feeding unit, the mixing unit, and the reactor unit.
  • at least one of the raw material feeding unit, the mixing unit, and the reactor unit may be immersed in a heating medium of which temperature can be controlled, or at least one of the raw material feeding unit, the mixing unit, and the reactor unit may be configured in a multilayer structure (for example, a two-layer tube or the like) to control the temperature from the inner side, the outer side, or both sides of the layers. Due to the presence of the temperature control unit, reaction yields and quality can be improved in a system that initiates a reaction by heat, a system that lowers a temperature to suppress a by-product formation, and the like.
  • the flow reactor of the present invention can be used, for example, for a chemical reaction operation, an extraction operation, a separation operation, a purification operation, or the like, which is an example of a chemical reaction operation for a fluid.
  • reaction solvents examples include an aliphatic hydrocarbon-based solvent such as n-hexane, cyclohexane, or methylcyclohexane; an aromatic hydrocarbon-based solvent such as benzene, toluene, or xylene; an ether-based solvent such as diethyl ether, diisopropyl ether, tetrahydrofuran, 2-methyltetrahydrofuran, 4-methyltetrahydropyran, methyl tert-butyl ether, 1,4-dioxane, or cyclopentyl methyl ether; a halogen-based solvent such as methylene chloride, chloroform, 1,1,1,-trichloroethane, or chlorobenzene; an ester-based solvent such as ethyl acetate, propyl acetate, or butyl acetate; a ketone-based solvent such as acetone,
  • the flow reactor of the present invention various chemical reactions can be performed, and there is no particular limitation on the chemical reaction. Since a reaction in the flow reactor is performed in a highly closed system, the flow reactor can be also applied to a reaction using a hazardous chemicals such as acrylonitrile, acrolein, sulfur dioxide gas, arsine, ammonia, carbon monoxide, chlorine, chloromethine, chloroprene, arsenic pentafluoride, phosphorus pentafluoride, ethylene oxide, nitrogen trifluoride, boron trifluoride, phosphorus trifluoride, hydrogen cyanide, diethylamine, disilane, sulfur tetrafluoride, silicon tetrafluoride, diborane, hydrogen selenide, trimethylamine, carbon disulfide, fluorine, bromomethyl, phosgene, phosphine, monogermane, monosilane, monomethylamine, or hydrogen sulfide.
  • a hazardous chemicals such as
  • the temperature in the reactor unit during a reaction is not particularly limited as long as it is equal to or lower than the boiling point of the reaction solvent and equal to or higher than the freezing point of the reaction solvent, and preferably -80°C or higher, more preferably -60°C or higher, further preferably -40°C or higher, preferably 200°C or lower, more preferably 180°C or lower, and further preferably 160°C or lower.
  • the flow rate of the reaction solution in the reactor unit is preferably 2 m/s or less, more preferably 1 m/s or less, and further preferably 0.8 m/s or less in order to suppress friction and prevent charging.
  • reaction time is preferably 60 minutes or less, more preferably 30 minutes or less, further preferably 15 minutes or less.
  • FIG. 6 shows a schematic view of an experimental apparatus.
  • a flow channel (hereinafter referred to as "conductive Teflon tube”; volume resistivity: 3.0 ⁇ •m; inner diameter: 2.0 mm ⁇ outer diameter: 3.0 mm ⁇ length: 2.6 m) 41 that was formed of PFA having a carbon-based conductive filler and had a cross-section of a single-layer structure was wound into coil form with a diameter of 80 mm, and one end of the flow channel 41 was connected to a water tap.
  • the ground was mounted on a position 3 cm inward from the discharge port of the conductive Teflon tube 41 in order to release the static electricity that traveled on the surface of the tube 41 to the outside.
  • a 2 liters disposable cup 42 made of polypropylene, which has high insulation properties, was placed near the discharge port of the conductive Teflon tube 41.
  • Teflon tube having no conductivity a flow channel
  • volume resistivity > 10 16 ⁇ •m
  • inner diameter 2.0 mm ⁇ outer diameter: 3.0 mm ⁇ length: 2.6 m
  • surface potential of the water stored in the disposable cup 42 was measured by a surface potential meter. The results are shown in Table 1. The measurement was carried out three times, and the evaluation was made based on the average value thereof.

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EP3476473A4 (fr) 2019-12-18
US20190126230A1 (en) 2019-05-02
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18W Application withdrawn

Effective date: 20201204